Interlocking asymmetric universal construction block

ABSTRACT

An asymmetrical interlocking universal construction element with a unique polygonal shape. It allows for constructing flat surfaces, internal corner, and external corner surfaces from a set consisting essentially of the same construction elements. It can be used to finish edges of an opening in a flat surface (e.g., for a door or window). Construction elements can be cut to size on-site. Assembly of two or more construction elements allows insertion of an S-shaped thin-walled metal element to provide load bearing capability. Application of the elements in construction assembly may use any raw material as long as it is shape-stable (i.e., capable of carrying its own weight only). The construction elements may be hollow or solid throughout.

BACKGROUND OF THE INVENTION

The use of interlocking construction blocks dates back to Greek and Roman times, and perhaps earlier. Keystones often held brick structures together. U.S. patent history of interlocking construction blocks dates back to the beginning of the twentieth century. The earlier blocks had simple interlocking construction. In 1916, J. J. Funsten invented a system of complex shape construction blocks with interlocking grooves (U.S. Pat. No. 1,167,746). A plurality of these blocks could mate together to produce strong integral structures. Funsten's blocks had planar external faces with S-shaped internal surfaces. In 1920, I Pomerantz invented interlocking construction blocks that were hollow (U.S. Pat. No. 1,332,409). This was followed by Baumann (U.S. Pat. No. 1,356,590), who invented a complex system of somewhat hollow construction blocks. Baumann's invented three different complex hollow symmetrical blocks interlocking blocks. Baumann needed the three blocks to create walls with corners. Most of this inventive activity in the United States took place prior to 1942. It picked up again during the 1960's, and continued to a much lesser extent until the present. In 1965, Nofziger invented two interlocking blocks that would mate together to form a post (U.S. Pat. No. 3,170,201). In 2003, Boot invented a complex system of interlocking concrete blocks to be used in construction (U.S. Pat. No. 6,508,041). Except for Nofziger, the inventors were mainly concerned with wall construction.

Generally, prior art construction block systems require different shaped blocks to be able to create a structure. The designs of most systems use symmetrical blocks, even though asymmetry is an advantage. A universal interlocking block is not available. The advantage of a universal block is to create floors, walls, and posts, which are the products of construction. Furthermore, the activity of inventors in this field has been limited to certain standard construction materials (e.g., brick, concrete, and wood). Construction elements fabricated from sheet metal do not exist. Interlocking insulation blocks are not available.

SUMMARY OF THE INVENTION

The Present Invention is an asymmetrical interlocking universal construction element with a unique polygonal shape. It allows for constructing flat surfaces, internal corner, and external corner surfaces from a set consisting essentially of the same construction elements. It can be used to finish edges of an opening in a flat surface (e.g., for a door or window). Construction elements can be cut to size on-site. The shape of the construction element enables production by cutting (extruding) with less than three-percent loss. The shape of the construction element enables production by cutting (extruding) units out of a slab of raw material with zero-loss. Assembly of two or more construction elements allows insertion of an S-shaped thin-walled metal element to provide load bearing capability. Application of the elements in construction assembly may use any raw material as long as it is shape-stable (i.e., capable of carrying its own weight only). The construction elements may be hollow or solid throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of the main construction element.

FIG. 2 shows the essentially planar polygonal shape of the main construction element.

FIG. 3 is an isometric view of four main construction elements mated together to form a traditionally shaped post.

FIG. 4 shows a series of main construction elements mated together to form internal and external corners.

FIG. 5A shows the polygonal face of the main construction element with an indicated cutting axis.

FIG. 5B shows the shapes of the faces of two new construction elements created by cutting the main construction element along the cutting axis of FIG. 5A.

FIG. 6 shows how the two new construction elements created in FIG. 5B may be mated together to form a traditionally shaped post.

FIG. 7 shows how one of the new construction elements may be mated with main construction elements to create an external corner.

FIG. 8 illustrates how a length of main construction elements may be mated together in a continuous straight line and finished at the ends using the new construction elements.

FIG. 9 is a top plan view of the perimeter of a structure fabricated by mating the construction elements together.

FIG. 10 is an isometric view of a prior art U-shaped bottom sheet tray having squared edges, which can be integrated into a structure comprising the construction elements so as to provide structural stability. The drawing shows how the element would be used as a bottom tray. However, when turned upside down, the element may be used as a cover.

FIG. 11 is an isometric view of a prior art S-shaped sheet element having squared edges, which can be integrated into a structure comprising the construction elements so as to provide load bearing capability.

FIG. 12 is a cross-section showing integration of the S-shaped into a construction element assembly.

FIG. 13A is an elevational view of an upright S-shaped element to which a horizontal U-shaped element is fastened in a direction perpendicular to the S-shaped element using bolts.

FIG. 13B is a top plan view of the structure shown in FIG. 13A.

FIG. 13C is an isometric view of the structure shown in FIG. 13A and FIG. 13B.

FIG. 14A is an elevational view of a window frame created in a wall under construction using the construction elements.

FIG. 14B is a cross-section showing how the window frame is connected to the wall of FIG. 14A.

FIG. 15 is a plan view of a hollow construction element. This element may be created by folding a web material into shape.

FIG. 16 is a plan view of a different hollow construction element.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is an isometric view of the construction element, 1, of the Present Invention. It is a three-dimensional structure having an essentially planar surface, 2, with a unique polygonal shape, wherein the planar surface is projected at right angles along a longitudinal axis having length, 3. This produces an element having a longitudinal axis, with two polygonal planar surfaces, one at each end having width, 4, and height 5. The polygons at both ends are congruent. A cross-sectional cut at any point along the longitudinal axis, perpendicular to the longitudinal axis, would be a polygon that is congruent to the two end polygonal planar surfaces.

FIG. 2 shows the planar polygonal surface 2. The points of the polygon are labeled ABCDEFGHIJKLMNOPQR. Surface 2 is a nineteen-sided irregular polygon having nineteen vertices and nineteen internal angles, all measuring ninety-degrees. Although the nineteen sides of the polygon intersect at ninety-degrees, they need not actually intersect at single points. The vertices may be curved.

FIG. 3 shows a traditionally shaped post, 6, (with a rectangular cross-section) fabricated by mating four construction elements, 1, together. The small rectangular shaped hole, 7, makes the post hollow allowing for a rod or wires to be inserted. The post is hollow along its entire longitudinal axis.

FIG. 4 shows two corner assemblies, 8 and 9, creating by mating a set of construction elements, 1. Assembly 8 shows an external corner, 10, and an internal corner, 13. It also shows an exterior surface, 12, and an interior surface, 14. Assembly 9 is a dual directional mirror image of Assembly 8, showing how an opposite corner may be constructed.

FIG. 5A shows the polygon, 2, of FIG. 2 with a cutting axis, Y-Y, drawn perpendicular to the width direction, 4, and parallel to the height direction, 5. Cutting the construction element along the Y-Y cutting axis parallel to the longitudinal axis, 3, produces two new construction elements, 15 and 16, shown in FIG. 5B. These two elements, 15 and 16, may mate together to form traditionally shaped post, 17, as shown in FIG. 6. Mating two elements, 15 and 16, together to form a post uses less material then mating four elements, 2, as shown in FIG. 3. The post of FIG. 3 uses four elements, 2, while the post of FIG. 6 uses only one element, 2, because elements, 15 and 16, are fabricated from only one element 2.

FIG. 7 shows how multiple construction elements may be mated together to create a straight line structure. Here, the linear assembly comprises a series of elements, 2, while element 15 finishes the left end. FIG. 8 shows a finished linear assembly constructed of a series of construction elements, 2, with the left end consisting of element 15 and the right end consisting of element 16. FIG. 9 is a top plan view showing construction of a typical structure using the linear assemblies suggested by FIGS. 7 and 8. The assemblies are interrupted by means for inserting doors and windows.

FIGS. 10, 11A, and 11B show components that are used in conjunction with construction element assemblies to lend structural stability and load bearing capability to the assemblies. FIG. 10 shows a U-shaped component, 18, having three squared edges, that is used for support in door and window frames. When component 18 is used as shown in FIG. 10, it is a support tray. However, if it is turned upside down, it serves as a cover. Component 18 is used both as a tray and a cover to support a window frame. The second component, 19, shown in FIGS. 11A and 11B, is used to provide load bearing capability for vertical beams consisting of assemblies of the construction elements of the Present Invention. The component is an S-shaped element with straight edges forming two halves of a square wave. FIG. 11A is an isometric view of the S-shaped component, 19, and FIG. 11B is a plan view of that component. FIG. 12 is a plan view showing how the S-shaped components are inserted between assembled vertical construction elements of the Present Invention. The S-shaped component adds vertical load bearing capability.

FIGS. 13A, 13B, and 13C show how a horizontal U-shaped component can be fastened to a vertical S-shaped component using bolts or other type fasteners. FIG. 13C is an isometric view of U-shaped component, 18, being used as a horizontal cover fastened to the vertical S-shaped component. FIG. 13A is an elevational view of the structure, while FIG. 13B is a top plan view of the structure.

FIG. 14A is an elevational view of a window frame 21 created in a wall under construction using the construction elements. The window frame consists of trim 22, header 23, and sill 25. Members 24 and 26, respectively support the window frame on top and bottom.

FIG. 14B is a plan view cross-section showing how the window frame is connected to the wall of FIG. 14A. Element 27 represents the internal sidewall sheeting, and 31 represents the surface finish. Element 28 is a profile post (such as is shown as element 19 in FIG. 13B) used to provide support stability. Element 29 is the construction block of the Present Invention (e.g., such as element 1 in FIG. 1), but in this case, it is fabricated from insulation foam. Note that it interlocks with another block immediately to its left. Element 30 is an L-Block (such as element 16 in FIG. 5B), and Element 32 is a G-Block (such as element 15 in FIG. 5B). As is the case with Element 29, Elements 30 and 32 are also fabricated from insulation foam. Insulation foam is inserted into positions 31.

The construction element of the Present Invention may be completely solid, partially hollow, or completely hollow. FIG. 15 is a plan view a completely hollow construction element. The construction element in this configuration may either be extruded or formed. If it is desired to form this shape, a web (such as a thin metal sheet made of steel or aluminum or a flexible plastic sheet) is folded to produce the nineteen sided polygonal structure. A use for such a structure would be as a post used to construct military perimeters. A perimeter can be fashioned from a linear assembly that extends to a desired height. When made of metal, this structure would have load bearing capability just as would the S-shaped component. After the hollow construction elements are assembled to form the perimeter, sand or cement may be poured into the construction elements from the top to stabilize the entire perimeter.

FIG. 16 is a plan view a partially hollow construction element. In this drawing, the construction element is mostly solid except for three rectangular through-holes passing through the entire construction element in a direction parallel to the longitudinal axis. Electric wiring or plumbing may be inserted into the holes. Of course, the through-holes may have any practical shape (e.g., they may be cylindrical).

Construction elements of the Present Invention may be load bearing, but they do not need to be load bearing. They can be fabricated as bricks, plaster, or wood logs. They may be made of plastic, which can be translucent or transparent. They may even be fabricated from insulating material. Insulating construction blocks may be cut on-site using a hot wire. Plastic or metal construction elements can be fabricated by extrusion or by pouring into a form. The construction elements may be made from any material that is shape-stable by itself or made shape-stable with glues or additives. They can be produced in any desired length along the longitudinal axis, and may be of any desired thickness. For example, the polygonal construction elements may be fabricated as patio bricks which would then be assembled to form a flat surface stone floor. The construction elements in vertical beams assembled from multiple elements may have construction elements made of different materials. For example, some of the elements could be made from structurally sound material, while others could be fabricated from insulating material. The construction elements may be assembled to form a wall whose interior surface is a smooth wall. On the other hand, sheet rock can be fastened to interior surfaces. Studs are not required for production of a wall. Plywood or other wood can be fastened to floor assemblies.

The asymmetric shape of the construction element is unlike any found in the prior art. The shape of the element allows for constructing a flat surface along with external and internal corner surfaces with a single type of construction element. Finishing edges of an opening in a flat surface (e.g., for a door or window) may be produced on-site by making a single horizontal cut of the construction assembly. U-shaped or S-shaped components may be added to the construction element assembly. The construction element design allows for mistake-proof assembly by low-skilled workers. The construction elements may be mass produced. A completely hollow construction element may be fabricated by folding sheet metal. Some elements from folded web material can be produced from a material having shape memory. Thus, all of the construction elements may be shipped flat to their destination, and then would be either folded or unfolded on-site.

As previously discussed, the vertices of the nineteen-sided polygon that forms the ends of the construction element may be curved as long as the sides of the polygon are essentially straight lines that are perpendicular to each other.

GLOSSARY

In drafting this patent application, the Inventor has chosen to be his own lexicographer. The definitions of terms presented herein supersede the plain and ordinary meaning of these terms.

1. U-Shape—A shape consisting of three essentially linear elements, wherein two of said elements are parallel to each other and each perpendicular to the third element.

2. S-Shape—A shape consisting of five essentially linear elements, wherein each of the first set of three elements are parallel to each other; wherein each of the second set of two of elements are parallel to each other; and wherein each of the first set of three elements is perpendicular to an element of the second set of two elements. The shape is shown in FIG. 11B.

3. Web Material (or Web or Webbing)—A thin sheet of essentially planar material that can be cut or bent into a desired shape. 

I claim:
 1. A three-dimensional construction element comprising: a) a length along a longitudinal axis; b) two essentially planar end surfaces having edges forming a perimeter comprising a closed irregular polygon with at least one end surface being perpendicular to the longitudinal axis, and wherein the end surfaces are separated from each other by the length of the construction element; c) wherein a cross-section of the construction element anywhere along its length and perpendicular to its longitudinal axis is a plane having edges that define a closed irregular polygon congruent to and parallel to the at least one end surface that is perpendicular to the longitudinal axis; d) wherein the irregular polygon formed by the edges of the at least one end surface that is perpendicular to the longitudinal axis and cross-section perpendicular to the longitudinal axis consists of nineteen sides, nineteen vertices, and nineteen internal angles all of which are essentially ninety degrees; and e) wherein any cross-section that is perpendicular to the longitudinal axis forms an irregular polygon that is congruent to and parallel to the at least one end surface that is perpendicular to the longitudinal axis.
 2. The construction element of claim 1, wherein each of the two end surfaces are congruent to the other and parallel to the other, and wherein both end surfaces are perpendicular to the longitudinal axis.
 3. The construction element of claim 1, wherein said construction element is produced using an extrusion process.
 4. The construction element of claim 1, wherein said construction element is solid throughout.
 5. The construction element of claim 1, wherein said construction element is hollow with a solid exterior having thickness.
 6. The construction element of claim 5, wherein the thickness of the solid exterior is small compared to a linear dimension of any edge of the irregular polygon.
 7. The construction element of claim 6, wherein the solid exterior is constructed from a web material.
 8. The construction element of claim 7, wherein the web material is a plastic sheet.
 9. The construction element of claim 7, wherein the web material is a metal sheet.
 10. The construction element of claim 7, wherein the solid exterior is produced by folding the web material into the shape of the irregular polygon.
 11. The construction element of claim 10, wherein the shape of the solid exterior is secured so that it cannot unfold.
 12. A beam, block, or post having a rectangular cross-section throughout that is produced by interlocking four of the construction elements of claim
 1. 13. A linear construction element formed by interlocking a plurality of the construction elements of claim 1 in a linear direction.
 14. A corner element comprising an external planar surface, an internal planar surface, an exterior corner angle being 90 degrees, and an internal corner angle being ninety degrees, wherein the corner construction element is produced by interlocking two linear construction elements of claim
 13. 15. The construction element of claim 1, wherein said construction element is cut along a planar axis parallel to the longitudinal axis and along the entire length, so as to produce a first smaller construction element and a second smaller construction element, such that both the first and second smaller construction elements can be oriented and interlocked to form a single rectangular beam, block, or post.
 16. A linear construction element comprising two end pieces, wherein said linear construction element is formed by interlocking a plurality of construction elements in a linear direction, wherein one end piece is the first smaller construction element of claim 15 and the second end piece is the second smaller construction element of claim
 15. 17. A corner element comprising an external planar surface, an internal planar surface, an exterior corner angle being 90 degrees, and an internal corner angle being ninety degrees, wherein the corner construction element is produced by interlocking construction elements with either the first or second smaller construction element of claim
 15. 18. An assembly of interlocking construction elements of claim 1, wherein at least one S-shaped sheet elements having squared edges is integrated into the interlocked edges.
 19. The assembly of claim 18, wherein the at least one S-shaped sheet element provides vertical load bearing capability to the assembly.
 20. An assembly of interlocking construction elements of claim 1 that rest upon a U-shaped bottom sheet tray having squared edges.
 21. An assembly of interlocking construction elements of claim 1, upon the top of which rests a cover comprising a U-shaped sheet element having squared edges.
 22. The construction element of claim 1 wherein the at least one vertex of the nineteen vertices are curved. 